Roller-die apparatus



May 22, 1962 K. R. REYNOLDS ROLLER-DIE APPARATUS 3 Sheets-Sheet 1 Filed May 2'7, 1959 INVENTOR. KENNETT R. REYNOLDS y 1962 K. R. REYNOLDS 3,035,628

ROLLER-DIE APPARATUS Filed May 27, 1959 3 Sheets-Sheet 2 Fig. 2

"M Ii' 46 INVENTOR. Fi 3 KENNETT R. REYNOLDS y 1962 K. R. REYNOLDS 3,035,628

ROLLER-DIE APPARATUS Filed May 2'7, 1959 3 Sheets-Sheet 3 Fig. 4

I40 INVENTOR.

KENNETT R. REYNOLDS Fig. 6 gg g A TTOR/VEYS United States Patent Office 3,035,628 Patented May 22, 1962 3,035,628 ROLLER-DIE APPARATUS Kennett R. Reynolds, 1725 Nason St., Alameda, Calif. Filed May 27, 1959, Ser. No. 816,348 Claims. (Cl. 15348) (Granted under Title 35, U.S. Code (1952), see. 266) The invention described herein may be manufactured and used by or for the Government of the United States of America for governmentfl purposes without the payment of any royalties thereon or therefor.

This invention relates to metal working equipment and more particularly to rolling apparatus for working airfoils or the like where the application of direct pressure is not feasible.

One of the major problems in the overhaul of military and commercial jet engines is the lack of a satisfactory means for straightening turbine nozzle vanes for reuse which have been warped due to extreme heat or otherwise distorted. Restoration of damaged vanes is desired economically to avoid the high replacement costs of new vanes.

Straightening turbine vanes is difficult because airfoil configurations have predetermined twists and multiple contoured surfaces. The vane surfaces and edges must be straightened to the original standard dimensions without collapsing or distorting the cross-sectional area of the vanes, especially if the vane has a cavity, such as Pratt and Whitney l-48 turbine nozzle guide vanes and the Pratt and Whitney J-57, first stage turbine nozzle guide vanes.

Prior methods for straightening turbine vanes relied on the application of direct pressure to only the trailing edge of the vane by means of an arbor press or the like. In many instances the applied pressure, being difficult to control, was too severe resulting in metal rupture. However, the primary limitation to the prior art method was that the remaining edges and surfaces of the vanes could not be straightened. Although vanes partially straightened by the prior art method were nevertheless pressed into service, maximum design efficiency of the engine could not be achieved because the reworked vanes did not have the original configuration or dimensions.

The present invention provides apparatus for Working and/or straightening a work piece, such as an airfoil turbine nozzle vane, by applying pressure along the vane at selected areas where required without collapsing or rupturing the work piece. The machine employs one or more dies against which is supported the work piece to be rolled. One of said dies consists of a plurality of segments having contoured working edges corresponding to the desired configuration of the corresponding part of the work piece, the opposite edges of the segments forming a composite concave cam surface. Gradual pressure on the object is applied through a reciprocating roller engaging the concave surface of the segmented die. The roller is journaled to a rocker arm pivoted on a trunnion supported by a column mounted to a base. The rocker arm is reciprocated by a suitable driving means.

Both rocker arm length and trunnion height are adjustable as well as the stroke of the rocker arm to regulate and control the area at which the pressure is applied to the work piece. Another die provides a cradle to support the ends of the work piece with provision for adjustment where the opposite ends of the work piece are twisted relatively, such as usually found in an airfoil.

A principal object of this invention is to provide apparatus capable of working a selected area of a work piece having an airfoil configuration.

Another object is to provide such an apparatus in which the working pressure can be applied gradually, and having means for indicating the applied pressure.

A further object is to provide an apparatus which is adjustable to straighten airfoils of different sizes and configurations.

Other objects and many of the attendant advantages of this invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a front isometric view of the invention apparatus adapted to be mounted on and driven by a conventional shaper;

F163. 2, 3, and 4 are longitudinal sectional views take along lines llil, Illl1l, and lV-IV, respectively, of PEG. 1;

FIG. 5 is a cross-sectional view taken of the nested die assembly on the carriage taken along line V-V of FIG. 4, the carriage being removed from the slide; and

FIG. 6 is a cross-sectional view of the carriage and lower die along line Vl-VI of FIG. 4- showing the pressure indicator and actuating linkage.

Referring to toe drawing where like reference numerals refer to similar parts throughout the drawing, there is shown in FIG. 1 a novel roller-die apparatus 10 mounted on and actuated by a conventional 24 inch shaper 12 partially shown in phantom lines. It is understood that although the invention apparatus is illustrated as adapted for use with a shaper as a matter of convenience, being available in most machine shops, it is not so limited and that the invention apparatus could be used in combination with other driving means.

Apparatus it) comprises a base plate 14 bolted to a shaper knee to, a front plate 13, slide plates 20, and a back plate 22, which plates form an enclosure for two adjustable knees to be described. As shown in FIGS. 1 and 2, a center support column 24 is anchored at one end to base plate 14 and is fabricated at the free end with a lateral longitudinal aperture 26 in which slides a rectangular central portion of a transverse trunnion bar 23. Bar 28 protrudes laterally from the sides of the column and the ends are cylindrically formed into a pair of trunnions 3-6 for pivotally supporting a corresponding pair of rocker arms 32.

Movement of the bar 28 vertically to change the height of the trunnions, being the pivotal axis of the rocker arms, is accomplished by manipulating an adjusting screw 34 threaded through an upper yoke end of the column and rotatably anchored in the transverse bar. Vertical movement of trunnion bar 28 is guided by a-pair of spaced shoulders 33 slidably engaging the sides of column 24, and front and rear guide plates 35.

It will be noted that roller-die apparatus 10 has provision for two identical work stations one on each side of a vertical plane passing through the center column, and the following description limited to the mechanism at one station, except where noted, will apply equally to both stations. It is understood that although two stations are preferred, the invention is not so limited and that one rocker arm and station could be utilized, if desired.

Each rocker arm 32 is fabricated to provide a longitudiual aperture 35 slidably to receive a support block 37, the latter having guide flanges 38 and being bored to receive and rotate about the respective trunnion. A retainer washer and screw 39 is threaded to the end of the trunnion securing block 37 thereto. The rocker arm length is also adjusted by a screw 40 threaded through an upper yoke end of the rocker arm and rotatably anchored in block 37. serrations 42 on rocker arm 32 are mated to serrated block 43 to effect a lock on support block 37 by cap screws 45. A roller 44 is journaled on shaft 46 to the lower end of the rocker arm and is adapted toengage the respective die assembly in a manner to be described.

The vertical adjustment of the trunnion and the adjustment in length of the associated rocker arms are considered to be important features of this invention as these adjustments provide means for applying pressure along a selected portion of the work piece that requires straightening or the like. Thus, pressure need not be applied to the remaining portion of the work piece avoiding unnecessary working and possible rupture of the work piece.

Where apparatus is installed on a conventional shaper, oscillatory movement is imparted to the rocker arms by link-age arm 48 pivoted to both the rocker arm and to an adapter plate '50 bolted to the shaper ram 52. Support plate 50 replaces the conventional tool holder and the clapper box mechanism (not shown) of the shaper. The degree of oscillatory movement of rocker arms can be selected by controlling the shaper ram stroke.

As shown in FIGS. 4 and 5, the work piece is a turbine nozzle van 54 adapted to be supported in a die assembly and between a pair of selected lower and upper dies corresponding to the particular type and size of vane being worked. The lower die comprises a pair of spaced shoes or cradles 56 each secured by four screws 58 to a carriage 60. Each cradle 56 engages a portion of the vane adjacent to the end, while a replaceable stop block 59 mounted to the cradle engages the flanged end portion of the vane as seen in FIG. 4.

For work pieces that are airfoil vanes, each shoe is adjustably supported on four jack screws 61 threaded in carriage 60 whereby the respective corners of the shoe can be raised or lowered above the carriage to vary the degree of twist in the vane about its longitudinal axis. Screws 58 lock the shoes in the adjusted position. Longitudinal movement of the vane on shoes 56 is limited by a pair of stop pads 62 secured to carriage 60, one of the stop pads being provided with an adjusting screw 64.

The upper die comprises a plurality of die segments 66 arranged in laterally abutting relation transversely the vane 54. Each die segment has a lower curved working surface 68 conforming to a finished corresponding surface of a master vane, and an upper straight surface 70. The upper surfaces of the adjacent die segments are machined to jointly form a concave cam surface conforming to an arc of a radius and extending longitudially of the vane, the cam surface adapted to be engaged at selected portions by the roller 44, depending on the degree of rocker arm movement.

The die segments are supported by cars 72 (FIG. 5) captured in an enlarged slot 73 in a cage 74 hinged at shaft 76 to carriage 60 whereby the upper caged die is pivoted to an open position, i.e., left hand rolling station in FIG. 1 for changing the vanes, and to a closed position, i.e., right hand rolling station in FIGS. 1, 4 and 5 for the rolling operation. Each die segment is independently slidable with respect to adjacent segments transversely the turbine vane to the extent permitted by the movement of ears 72 in slot 73, the relative position of each segment depending on the amount of deformity in the vane engaging the respective die segment. A sheet metal segment buifer strip 78 may be secured to cage 74 for disposition between roller 44 and upper surfaces 70 of the die segments. The ends of strip 78 are secured to a set of shim blocks 79 being adjustable to conform the strip to the curvature of the particular set of die seg- .ments being employed.

The lower surface of carriage 60 is grooved at 80 to engage a slide 82 extending in parallel relation to the trunnions to enable the carriage to be moved from a closed position of the die assembly directly beneath the roller, to a laterally open position of the die assembly where the die assembly is laterally offset from the roller to permit opening of the dies. Carriage 60 is moved by the operator to the two foregoing positions through a handcrank and associated linkage 84.

Pivotal movement of cage 74 housing the upper die set is automatically controlled by the movement of carriage 60 through a crank arm 86 keyed to shaft 76. A cam follower 87 on crank arm 86 is adapted to engage a semicylindrical cam groove 88 on a cam plate 90 secured to slide 82, whereby the cage is pivoted to an open position, when the carriage is moved from a position under the roller, and pivoted and locked to a closed position when the carriage is moved to a position under the roller.

Pressure is applied to the closed die assembly by roller 44 through a vertically adjustable knee 92 (FIG. 3) on which is mounted corresponding slide 82 and the associated carriage. It is understood that each rolling station is provided with a separate adjustable knee, one on each side of center column 24, although the knees may be jointly operated in a manner presently to be described. Each adjustable knee 92 comprises a lower wedge 94 having a top roller surface 96 sloping upwardly toward rear plate 22, and an upper wedge 98 having a corresponding bottom sloping surface 99. Lower wedge 94 has a pair of transverse horizontal slots 100, one slot being shown in FIG. 3, in which are journaled a plurality of roller bearings 102 for rolling engagement on and transversely the top of base plate 14. Sloping surface 99 is provided with a pair of transverse slots 104, one of which is shown in FIG. 3, in which are journaled a plurality of roller bearings 106 adapted to engage surface 96 of the lower wedge.

Upper wedge 98 is laterally restrained between front and rear plates 18 and 22, respectively, so that horizontal movement of lower wedge 94 across base plate 14 results in a corresponding vertical movement of upper wedge 98 riding on sloping surface 96. It will be recalled that slide 82 (not shown in FIG. 3) is supported on upper wedge 98 and thus the slide and associated die assembly is imparted a corresponding movement. As shown in FIG. 3, lower wedge 94 has a central keyway 108 to receive a downwardly projecting key 110 on upper wedge 98 to maintain constant contact between wedges during relative movement.

Transverse movement of lower wedge 94, and corresponding movement of the die assembly with relation to roller 44 is controlled by the operator through a handwheel 112 (FIGS. 1, 2 and 3) located in front of the rolling apparatus. Handwheel 112 is threaded to and keyed at 114 to one end of a screw 116 extending from front to back of apparatus 10, the screw being centrally threaded through the base of center support column 24 fixed to shaper knee 16. Translatory movement of the screw forward or rearward depends on the direction of handwheel rotation.

A front and rear tie bar 118 and 120, respectively, have center bored openings 121 journaled to respective smooth portions 122 and 124 adjacent the ends of screw 116 to enable the latter to rotate with respect to the tie bars. Suitable thrust bearings 126 are provided on each side of the journaled portions. Corresponding ends of tie bars 118 and are screwed at 128 (FIGS. 1 and 3) to the respective front and back of lower wedge 94, whereby the lower wedges are driven by rotation of screw 116. Screwed on a central portion of rear tie bar 120 is a bracket 130 through which is threaded a stop screw 132 adapted to abut center column 24 to limit the degree of rotation of screw 116 and the corresponding movement of lower wedge 94.

It is apparent that the adjustable knees provide a means for gradually applying pressure on the nested die assembly and to the vane supported therebetween until it is finally straightened. To enable the operator accurately to ascertain when the vane has been straightened the correct amount, a displacement dial indicator 134 (FIGS. 1 and 6) is supported in a bracket 136 screwed to extension 138 of carriage 60. A rocker arm 140 centrally pivoted at 142 to the underside of carriage terminates in two upstanding fingers 144 and 146. A flat tip of finger 144 engages a dial followef 148 for moving the dial pointer. Finger 146 projects through carriage opening 150 into the space between shoes 56 to bear against a lower portion of vane 54 supported therebetween. Compression coil spring 151 maintains finger 146 in engagement with the vane throughout the straightening operation. Arm 140 is accommodated in opposed longitudinal slots 152 and 154 in the carriage and slide, respectively.

A typical operation in the straightening of given type and size turbine nozzle vanes is as follows. The correct corresponding die segments 66 and shoes 56 are selected and installed on the cage and carriage, respectively, at each rolling station, shoes 56 being adjusted in height by screws 58 and 61 on the carriage according to the contour of the vane ends. The trunnion bar 28 and rocker arms 32 are adjusted by screws 34 and 40, respectively, depending on the die segments employed and the particular area along the vane length to be straightened.

Prior to the initial operation, and preferably at the start of each day of operation, the operator places -a master vane, or a new vane, on shoes 56 and closes cage 74 nesting the vane therebetween. The indicator on dial 134 is set at zero (FIG. 6) which is the final desired reading of a worked vane.

The actual rolling operation is commenced by operating ram 52 at the selected stroke which drives rocker arm in a reciprocating movement over the closed die assembly. Handwheel 112 is gradually rotated in a direction to draw lower wedge 94 forward, which, in turn, raises upper wedge 98 forcing the die assembly against the oscillating roller. As the pressure is applied the roller gradually works the vane through the dies only at the part of the vane that needs to be worked. The vane being worked is gradually straightened until the dial indicates zero reading at which time the operator knows the vane has been restored to the same contour as the master vane. After the rolling operation is thus completed, the knees are lowered and handle 84 is actuated to slide carriage of} from under the respective roller. At the end of the sliding movement, cage 74 is raised to the open position by engagement of cam follower 87 and cam 88. The restored vane is removed and a vane to be worked is inserted in its place and the foregoing operation is repeated. Although the operation was described with reference to one station, both stations can be operated simultan-:ously or alternately as the situation may dictate.

The rolling apparatus of this invention achieves the selective straightening of collapsible work pieces, such as turbine vanes, at particular areas where required. By applying the straightening pressure to only a damaged area, over bending, rupturing, and the stressing of good areas are avoided. The above objectives are accomplished by providing the trunnion and rocker arm with certain adjustments and by using a roller and a segmented die.

Obviously many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as Specifically described.

I claim:

1. Rolling apparatus for a work piece comprising a base, an upright having a trunnion, a rocker arm pivotally supported on said trunnion for oscillatory movement thereabout, a roller journaled to one end of said rocker arm, means for adjusting the length of the rocker arm between the roller and the trunnion, a die supported on said base and having a working surface corresponding to the desired contour of a work piece positioned thereagainst, said die composed of a plurality of independently movable adjacent die segments forming an outer composite concave surface having a radius and extending in the direction of the path of said roller for engagement by the roller, means for applying gradually a pressure on said die through said roller, and means of oscillating said 6 rocker arm with the roller in engagement with said die whereby a selected portion of the Work piece is Worked.

2. The apparatus of claim 1 wherein means are provided to indicate the amount of displacement of the work piece being rolled, said indicating means being actuated by linkage adapted to engage the work piece.

3. Rolling apparatus for straightening a turbine vane comprising a base, an upright having a trunnion, means for adjusting the height of the trunnion above the base, a rocker arm supported on said trunnion for oscillatory movement thereabout, a roller journaled to one end of said rocker arm, means for adjusting the length of the rocker arm between the trunnion and the roller, a pair of replaceable dies supported on said base between which the vane to be worked is positioned, said dies having opposed working surfaces conforming to respective surfaces of a properly configured vane, one of said dies composed of a plurality of independently movable adjacent segments and having an outer composite concave surface having a radius and extending in the direction of the path of said roller for engagement by the roller, means for applying gradually a pressure on said dies through said roller, and means of oscillating said rocker arm while the roller is in engagement with said die whereby a preselected portion of the vane is Worked.

4. The apparatus of claim 3 wherein said rocker is supported to the trunnion by a block having an aperture through which the trunnion extends freely, said rocker arm is longitudinally slotted slidably to receive said block, and threaded means extending between an end of the arm opposite the roller and the block for adjusting the length of the arm between the roller and the trunnion.

5. The apparatus of claim 3 wherein the stroke length oscillating means can be controlled.

6. The apparatus of claim 3 wherein the dies are supported on a cage, means for elevating and depressing said cage with respect to the base for applying said pressure.

7. The apparatus of claim 3 wherein said other die comprises at least a pair of spaced shoes for supporting respective ends of said vane, and means provided for raising or lowering the ends of both shoes to accomodate vanes having various degrees of twist.

8. The apparatus of claim 6 wherein said means for raising and lowering said cage is in an adjusting knee consisting of a pair of sliding Wedges.

9. In combination with a shaper ram comprising an apparatus for straightening a turbine vane including a base adapted to be supported on the shaper knee, an upright having a trunnion means for adjusting the height of the trunnion above the base, a rocker arm supported on said trunnion for oscillatory movement thereabout, a roller journaled to one .end of said rocker arm, means for adjusting the length of the rocker arm between the trunnion and the roller, a replaceable die supported 'on said base and having a working surface conforming to the finished shape of the vane positioned thereagainst, said die composed of a plurality of segments having an outer concave recess for engagement by the roller, means for applying gradually a pressure on said dies through said roller, linkage connecting said rocker arm to the shaper ram for oscillating said rocker arm while the roller is in engagement with said die whereby a selected portion of the object is worked.

10. Apparatus for straightening a turbine vane comprising a base, an upright having a pair of oppositely disposed trunnions, means for adjusting the height of the trunnions above the base, a rocker arm supported on each trunnion for oscillatory movement thereabout, a roller journaled to one end of each rocker arm, means for adjusting the length of each rocker arm between the respective roller and the trunnion, a pair of replaceable dies for each rocker arm supported on a carriage between which the vane to be worked is positioned, said dies having working surfaces conforming to respective surfaces of a properly configured vane, one of said dies composed of a plurality of segments and having an outer concave recess for engagement by theroller, means for elevating each carriage above the base for applying gradually a pressure on said dies through said respective roller, and means for oscillating said rocker arms while the rollers are in engagement with said dies whereby a selected portion of the respective vane is worked.

References Cited in the file of this patent UNITED STATES PATENTS 192,300 Smith June 19, 1877 Shoemaker Jan. 13, Norwood July 1, Sponsel Sept. 11, Weaver Nov. 2, Leighton Jan. 5, Doran May 11, Kennedy May 13, Johnson Apr. 2, Dakin June 24, Tegarden Mar. 5, 

